Xtender XTM 2000-12 User manual

Brand: Xtender

Model: XTM 2000-12

Type: User manual

This manual is also suitable for

Studer Innotec SA 2015 – V4.6.0

4O9A

Xtender, Unit combining inverter,

battery charger and transfer system

User manual

XTS 900-12

XTS 1200-24

XTS 1400-48

XTM 1500-12

XTM 2000-12

XTM 2400-24

XTM 3500-24

XTM 2600-48

XTM 4000-48

H 3000-12

XTH 5000-24

XTH 6000-48

XTH 8000-48

Common Accessories

Temperature sensor.............................................. BTS-01

Accessories XTM/XTS

Remote command module................................ RCM-10

Accessories XTS

External cooling fan............................................. ECF-01

External auxiliary relay module........................... ARM-02

Studer Innotec SA

Xtender

Studer Innotec SA

Xtender

User manual V4.6.0 3

SUMMARY

1 INTRODUCTION.......................................................................................................................................5

2 GENERAL INFORMATION .......................................................................................................................5

2.1 Operating instructions ......................................................................................................................... 5

2.2 Conventions .......................................................................................................................................... 6

2.3 Quality and warranty ........................................................................................................................... 6

2.3.1 Exclusion of warranty ....................................................................................................................... 7

2.3.2 Exclusion of liability ........................................................................................................................... 7

2.4 Warnings and notes ............................................................................................................................. 7

2.4.1 General .............................................................................................................................................. 7

2.4.2 Precautions when using batteries ................................................................................................. 8

3 ASSEMBLY AND INSTALLATION .............................................................................................................9

3.1 Handling and moving .......................................................................................................................... 9

3.2 Storage ................................................................................................................................................... 9

3.3 Unpacking .............................................................................................................................................. 9

3.4 Installation site ....................................................................................................................................... 9

3.4.1 XTM and XTH ..................................................................................................................................... 9

3.5 Fastening ................................................................................................................................................ 9

3.5.1 Fastening of the XTH model .........................................................................................................10

3.5.2 Fastening of the XTM model ........................................................................................................10

3.5.3 Fastening of the XTS model ..........................................................................................................10

3.6 Connections ........................................................................................................................................11

3.6.1 General recommendations .........................................................................................................11

3.6.2 Connection compartment, XTH and XTM models ..................................................................12

3.6.3 Connection compartment, XTS model .....................................................................................13

3.6.4 Elements of the connection compartments ............................................................................14

3.6.5 Tightening torque ...........................................................................................................................15

3.6.6 Max permissible cable cross-sections ........................................................................................15

4 CABLING ...............................................................................................................................................16

4.1 Choice of system ................................................................................................................................16

4.1.1 Hybrid stand-alone systems .........................................................................................................16

4.1.2 Grid-connected back-up systems ..............................................................................................16

4.1.3 Integrated mobile systems ...........................................................................................................16

4.1.4 Multi-unit systems ............................................................................................................................16

4.1.5 Distributed minigrid ........................................................................................................................17

4.2 Earthing system ...................................................................................................................................17

4.2.1 Mobile installation or installation connected to the grid via plug connector ...................17

4.2.2 Stationary installation ....................................................................................................................18

4.2.3 Installation with automatic PE-neutral switching .....................................................................18

4.2.4 Lightning protection ......................................................................................................................18

4.3 Recommendations for dimensioning the system .........................................................................18

4.3.1 Dimensioning the battery .............................................................................................................18

4.3.2 Dimensioning the inverter .............................................................................................................19

4.3.3 Dimensioning the generator ........................................................................................................19

4.3.4 Dimensioning the renewable energy sources..........................................................................19

4.4 Wiring diagrams ..................................................................................................................................19

4.5 Connecting the battery ....................................................................................................................19

4.5.1 Battery cable cross-section and DC protective devices .......................................................20

4.5.2 Connecting the battery (Xtender side) .....................................................................................20

4.5.3 Fuse mounting on battery positive pole (XTM only) ................................................................21

4.5.4 Battery-side connection ...............................................................................................................21

4.5.5 Earthing of battery .........................................................................................................................22

4.5.6 Connecting the consumers at the AC output .........................................................................22

4.5.7 Connecting the AC supply sources ...........................................................................................23

4.5.8 Wiring auxiliary contacts ...............................................................................................................23

4.5.9 Connecting the communications cables .................................................................................23

5 XTENDER PARAMETER SETTINGS ..........................................................................................................24

5.1 Basic parameter settings in the XTS.................................................................................................24

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Xtender

User manual V4.6.0 4

6 POWERING UP THE INSTALLATION .......................................................................................................25

6.1 Connecting the battery ....................................................................................................................25

6.2 Putting the Xtender(s) in operation using the main ON/OFF switch (1) if present .................25

6.3 Connecting the consumers at the output ....................................................................................25

6.4 Activating the input circuit breaker(s) (H) .....................................................................................25

7 DESCRIPTION OF THE MAIN FUNCTIONS ............................................................................................26

7.1 Inverter ..................................................................................................................................................26

7.1.1 Automatic load detection (load search) .................................................................................26

7.2 Transfer relay ........................................................................................................................................26

7.2.1 Type of detection of AC input loss (UPS) ...................................................................................27

7.2.2 Limiting the AC input current "Input limit" ..................................................................................27

7.3 Battery charger ...................................................................................................................................28

7.3.1 Working principle ...........................................................................................................................28

7.3.2 Battery charger current setting ...................................................................................................30

7.3.3 Battery protection ..........................................................................................................................30

7.4 Xtender protection ............................................................................................................................30

7.4.1 Protection in case of overload ....................................................................................................30

7.4.2 Protection against overvoltage ..................................................................................................30

7.4.3 Protection against overheating ..................................................................................................30

7.4.4 Protection against battery reverse polarity ..............................................................................31

7.5 Auxiliary contacts ...............................................................................................................................31

7.6 Real time clock ...................................................................................................................................31

7.7 Remote entry (Remote control on/off) ..........................................................................................32

7.7.1 XTH model ........................................................................................................................................32

7.7.2 XTM and XTS models ......................................................................................................................32

7.7.3 Remote entry controlled by an auxiliary relay .........................................................................33

8 MULTI-UNIT CONFIGURATION .............................................................................................................33

8.1 Three-phase system............................................................................................................................34

8.2 Increasing the power by paralleling units......................................................................................34

8.3 Combined system ..............................................................................................................................34

8.4 Enlargement of an existing installation ...........................................................................................34

9 ACCESSORIES .......................................................................................................................................35

9.1 Remote control RCC-02/-03 .............................................................................................................35

9.2 BTS-01 temperature sensor ...............................................................................................................36

9.2.1 Connecting the temperature sensor (BTS-01) ..........................................................................36

9.3 Remote control module RCM-10 (XTM/XTS) ..................................................................................36

9.3.1 Connection of the RCM-10 module ...........................................................................................36

9.4 Time and communication module TCM-01(XTS) ..........................................................................37

9.5 Auxiliary relay module ARM-02 (XTS) ...............................................................................................37

9.6 External cooling fan unit ECF-01 (XTS) ............................................................................................37

10 OTHER XTENDER SYSTEM COMPATIBLE DEVICES ...............................................................................38

10.1 Battery status processor BSP-500/-1200 ..........................................................................................38

10.2 Communication module Xcom-232i ..............................................................................................38

10.3 MPPT solar charge controller VarioTrack/VarioString ..................................................................38

10.4 Communication sets Xcom-LAN/-GSM ..........................................................................................38

10.5 Communication module Xcom-SMS ..............................................................................................38

11 CONTROL ..............................................................................................................................................39

11.1 Main on/off control ............................................................................................................................39

11.2 Display and control panel ................................................................................................................39

12 MAINTENANCE OF THE INSTALLATION ...............................................................................................41

13 PRODUCT RECYCLING .........................................................................................................................41

14 EC DECLARATION OF CONFORMITY ..................................................................................................41

15 COMMENTS TO DRAWINGS IN THE APPENDIX ...................................................................................42

16 DRAWING ELEMENTS (DC SIDE) ..........................................................................................................44

17 FIGURE ELEMENTS (AC PART) ..............................................................................................................45

18 MECHANICAL DIMENSION AND MOUNTING ELEMENTS ...................................................................46

19 NAMEPLATE (FIG. 1B) ...........................................................................................................................46

20 TABLE OF FACTORY DEFAULT PARAMETER SETTINGS .........................................................................47

21 TECHNICAL DATA .................................................................................................................................54

Studer Innotec SA

Xtender

User manual V4.6.0 5

1 INTRODUCTION

Congratulations! You are about to install and use a device from the Xtender range. You have chosen

a high-tech device that will play a central role in energy saving for your electrical installation. The

Xtender has been designed to work as an inverter / charger with advanced functions, which can be

used in a completely modular way and guarantee the faultless functioning of your energy system.

When the Xtender is connected to a generator or network, the latter directly supplies the consumers,

and the Xtender works like a battery charger and backup device if necessary. The powerful battery

charger has an exceptionally high efficiency and a power factor correction (PFC) close to 1. It

guarantees excellent battery charging in all situations. The charge profile is freely configurable

according to the type of battery used or the method of usage. The charge voltage is corrected

depending on the temperature, thanks to the optional external sensor. The power of the charger is

modulated in real time dependent according to the demand of the equipment connected at the

Xtender output and the power of the energy source (network or generator). It can even temporarily

backup the source if the consumer demand exceeds the source capacity.

The Xtender continuously monitors the source to which it is connected (network or generator) and

disconnects itself immediately if the source is missing, disturbed or does not correspond to the quality

criteria (voltage, frequency, etc.). It will then function in independent mode, thanks to the integrated

inverter. This inverter, which has an extremely robust design, benefits from Studer Innotec’s many

years of experience and expertise in this area. It could supply any type of load without faults, enjoying

reserves of additional power that is unmatched in the market. All your equipment will be perfectly

provided with energy and protected from power outages in systems where energy supply is

unpredictable (unreliable network) or voluntarily limited or interrupted, such as hybrid installations on

remote sites or mobile installations.

The parallel and/or three-phase network operation of the Xtender offers modularity and flexibility and

enables optimum adaptation of your system to your energy requirements.

The RCC-02/-03 control, display and programming centre (optional) enables optimum configuration

of the system and guarantees the operator continuous control for all important parameters in the

installation.

In order to guarantee flawless commissioning and functioning of your installation, please read this

manual carefully. It contains all the necessary information relating to the functioning of the

inverters/chargers in the Xtender series. The setting up of such a system requires special expertise and

may only be carried out by qualified personnel familiar with the applicable local regulations.

2 GENERAL INFORMATION

2.1 OPERATING INSTRUCTIONS

This manual is an integral part of each inverter/charger from the Xtender series.

It covers the following models and accessories

Inverter/charger:

XTH 3000-12 – XTH 5000-24 – XTH 6000-48 – XTH 8000-48

XTM 1500-12, XTM 2000-12, XTM 2400-24,

XTM 3500-24, XTM 2600-48, XTM 4000-48

XTS 900-12, XTS 1200-24, XTS 1400-48

External cooling fan: ECF-01

Temperature sensor: BTS-01

Remote command module: RCM-10

Auxiliary relay module: ARM-02

For greater clarity, the device is referred to in this manual as Xtender, unit or device, when the

description of its functioning applies indiscriminately to different Xtender models.

These operating instructions serve as a guideline for the safe and efficient usage of the Xtender.

Anyone who installs or uses an Xtender can rely completely on these operating instructions, and is

bound to observe all the safety instructions and indications contained. The installation and

commissioning of the Xtender must be entrusted to a qualified professional. The installation and

usage must conform to the local safety instructions and applicable standards in the country

concerned.

Also for 120Vac model (-01)

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Xtender

User manual V4.6.0 6

2.2 CONVENTIONS

This symbol is used to indicate the presence of a dangerous voltage that is sufficient to

constitute a risk of electric shock.

This symbol is used to indicate a risk of material damage.

This symbol is used to indicate information that is important or which serves to optimise your

system.

This symbol placed on the product indicates that its surfaces may reach temperatures

higher than 60°C.

This symbol placed on the product indicates that its use must follow the instructions in the

user’s manual.

All values mentioned hereafter, followed by a parameter number indicate that this value may be

modified using the RCC-02/-03 remote control.

In general, the default values are not mentioned and are replaced by a parameter number in the

following format: {xxxx}. The default values for this parameter are specified in the defaults parameter

table, p. 47.

All parameter values modified by the operator or installer must be transferred into the same

table. If a parameter not appearing in the list (advanced parameters) has been modified

by an authorised person with technical knowledge, they will indicate the number of the

modified parameter(s), the specifications of the parameter(s) and the new value set, at the

end of the same table.

All figures and letters indicated in brackets or in square brackets refer to items that can be found in

the separate manual "Appendix to the installation and operating instructions" supplied with the

device. In this appendix, these figures and letters are encircled.

 The figures in brackets refer to elements belonging to the Xtender.

 The uppercase letters in brackets refer to AC cabling elements.

 The lowercase letters in brackets refer to battery cabling elements.

 The comments on figures and items of the appendix are given starting on p. 42.

2.3 QUALITY AND WARRANTY

During the production and assembly of the Xtender, each unit undergoes several checks and tests.

These are carried out with strict adherence to the established procedures. Each Xtender has a serial

number allowing complete follow-up on the checks, according to the particular data for each

device. For this reason it is very important never to remove the type plate (appendix 1 – fig. 3b) which

shows the serial number. The manufacture, assembly and tests for each Xtender are carried out in

their entirety by our factory in Sion (CH). The warranty for this equipment depends upon the strict

application of the instructions appearing in this manual.

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Xtender

User manual V4.6.0 7

2.3.1 Exclusion of warranty

No warranty claims will be accepted for damage resulting from handling, usage or processing that

does not explicitly appear in this manual. Cases of damage arising from the following causes are

notably excluded from the warranty:

 Surge voltage on the battery input (for example, 48 V on the battery input of an XTH 3000-12)

 Incorrect polarity of the battery

 The accidental ingress of liquids into the device or oxidation resulting from condensation

 Damage resulting from falls or mechanical shocks

 Modifications carried out without the explicit authorisation of Studer Innotec

 Nuts or screws that have not been tightened sufficiently during the installation or

maintenance

 Damage due to atmospheric surge voltage (lightning)

 Damage due to inappropriate transportation or packaging

 Disappearance of original marking elements

2.3.2 Exclusion of liability

The placement, commissioning, use, maintenance and servicing of the Xtender cannot be the

subject of monitoring by Studer Innotec. Therefore, we assume no responsibility and liability for

damage, costs or losses resulting from an installation that does not conform to the instructions,

defective functioning or deficient maintenance. The use of a Studer Innotec inverter is the

responsibility of the customer in all cases.

Studer Innotec shall in no event be liable for consequential, incidental, contingent or special

damages, even if having been advised of the probability of such damages. This equipment is neither

designed nor guaranteed to supply installations used for vital medical care nor any other critical

installation carrying significant potential damage risks to people or the environment.

Studer Innotec assumes no responsibility for the infringement of patent rights or other rights of third

parties that result from using the inverter.

Studer Innotec reserves the right to make any modifications to the product without prior notification.

2.4 WARNINGS AND NOTES

2.4.1 General

This manual is an integral part of the device and must be kept available for the operator

and installer. It must remain close to the installation so that it may be consulted at any time.

The parameter table available at the end of the manual (p. 47) must be kept up to date in the event

of modification of the parameters by the operator or installer. The person in charge of installation

and commissioning must be wholly familiar with the precautionary measures and the local

applicable regulations.

When the Xtender is running, it generates voltage that can be potentially lethal. Work on or

close to the installation must only be carried out by thoroughly trained and qualified

personnel. Do not attempt to carry out on-going maintenance of this product yourself. The

Xtender or the generator connected to it may start up automatically under certain

predetermined conditions.

When working on the electrical installation, it is important to be certain that the source of

DC voltage coming from the battery as well as the source of AC voltage coming from a

generator or network have been disconnected from the electrical installation.

Even when the Xtender has been disconnected from the supply sources (AC and DC), a

dangerous voltage may remain at the outputs. To eliminate this risk you must switch the

Xtender OFF using the ON/OFF button (1). After 10 seconds the electronics is discharged

and intervention may take place without any danger.

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Xtender

User manual V4.6.0 8

All elements connected to the Xtender must comply with the applicable laws and regulations.

Persons not holding written authorisation from Studer Innotec are not permitted to proceed with any

change, modification or repairs that may be required. Only original parts may be used for authorised

modifications or replacements.

This manual contains important safety information. Read the safety and working instructions carefully

before using the Xtender. Adhere to all the warnings given on the device as well as in the manual,

by following all the instructions with regard to operation and use.

The Xtender, except XTS, is only designed for indoor use and must under no circumstances be

subjected to rain, snow or other humid or dusty conditions. The maximum specifications of the device

shown on the type plate, as at fig. 1b, must be adhered to.

In the event of use in motorised vehicles, the Xtender must be protected from dust, splash water and

any other humid condition. It must also be protected from vibration by installing absorbent parts.

The Xtender can be installed at altitudes up to 3000m. For installations at higher altitudes,

please contact Studer Innotec SA. The Xtender is in overvoltage category III, which

indicates that it can be installed directly after the protection device at the entrance of

a building.

2.4.2 Precautions when using batteries

The batteries should only be chosen, dimensioned and installed by qualified personnel,

trained in this specific area.

Lead-acid or gel batteries produce a highly explosive gas with normal use. No source of

sparks or fire should be present in the immediate vicinity of the batteries. The batteries

must be kept in a well-ventilated place and be installed in such a way as to avoid

accidental short-circuits when connecting.

Never try to charge frozen batteries.

When working with the batteries, a second person must be present in order to lend

assistance in the event of problems.

Sufficient fresh water and soap must be kept to hand to allow adequate and immediate

washing of the skin or eyes affected by accidental contact with the acid.

In the event of accidental contact of the eyes with acid, they must be washed carefully

with cold water for 15 minutes. Then immediately consult a doctor.

Battery acid can be neutralised with baking soda. A sufficient quantity of baking soda

must be available for this purpose.

Particular care is required when working close to the batteries with metal tools. Tools such

as screwdrivers, open-ended spanners, etc., may cause short circuits. Sparks resulting

from these short-circuits can cause the battery to explode. Therefore, tools with insulated

handles should be used and they should never be left to rest on top of the batteries.

When working with the batteries, all metal jewellery such as rings, watches with a metal

bracelet, earrings, etc., must be taken off. The current supplied by the batteries during a

short circuit is sufficiently powerful to melt the metal and cause severe burns.

Batteries at the end of their life-cycle should be recycled in accordance with directives

from the responsible local authorities or the battery supplier. The batteries should never

be exposed to fire as they may explode. Under no circumstances should you try to take

apart or dismantle the battery, as they contain toxic and polluting materials. For

ungrounded battery systems, always check that they are not inadvertently grounded

before starting work on the batteries.

Always follow carefully the instructions of the battery manufacturer.

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Xtender

User manual V4.6.0 9

3 ASSEMBLY AND INSTALLATION

3.1 HANDLING AND MOVING

The weight of the Xtender can be up to 50kg depending upon the model. Use an appropriate lifting

method as well as help from a third party when installing the equipment.

3.2 STORAGE

The equipment must be stored in a dry environment at an ambient temperature of between

-20°C and 60°C. It stays in the location where it is to be used a minimum of 24 hours before being set up.

3.3 UNPACKING

When unpacking, check that the equipment has not been damaged during transportation and that

all accessories listed below are present. Any fault must be indicated immediately to the product

distributor or the contact given at the back of this manual.

Check the packaging and the Xtender carefully.

Standard accessories:

 Installation and operating instructions, c.f. Appendix 1.

 Mounting plate for XTH and XTS– fig. 2a (25)(26).

 One set of cable glands on the unit and/or apart.

 Four M6 screws and washer for XTS to assemble the support and the enclosure.

3.4 INSTALLATION SITE

3.4.1 XTM and XTH

Devices in the XTM and XTH range are designed for indoor use (IP20) and the place of installation

must satisfy the following criteria:

 Protected from any unauthorised person.

 Protected from water and dust and in a place with no condensation.

 It must not be situated directly above the battery or in a cabinet with it.

 No easily inflammable material should be placed directly underneath or close to the Xtender.

 Ventilation apertures must always remain clear and be at least 20cm from any obstacle that

may affect the ventilation of the equipment.

 In mobile applications, it is important to select an installation site that ensures as low a

vibration level as possible.

 According to the IEC/EN 62109-1 norm, the level of pollution at the mounting place should

not exceed PD2 (second-degree environment), which means that there can be pollution as

long as it is not electrically conductive. XTS

XTS range appliances have a high grade of protection (IP54). They can therefore be installed

outdoors, with exposure to dust and water splashes. It is recommended to avoid locations particularly

exposed to salt-water splashes which are extremely aggressive (for instance under a vehicle chassis)

or to solvent (motor oil) that can attack all non-metallic parts of the enclosure. Also avoid installing

the XTS in direct sunlight or near a heat source (i.e. engine compartment). The presence of a heat

source may reduce significantly the nominal power of the unit.

Reduce as much as possible exposure to sudden temperature changes as a variation in temperature

may cause undesired condensation inside the enclosure.

The 4 mounting screws of the enclosure must be completely tightened with a torque of

5Nm in order to guarantee the IP 54 protection index. Any unused cable glands should

be closed in a way that guarantees at least the same level of protection.

3.5 FASTENING

The Xtender is a heavy unit and must be mounted to a non-flammable support (wall)

designed to bear such a load

The Xtender must be installed vertically onto heavy-duty material (concrete or metallic wall) and

positioned vertically with cable glands oriented down. A sufficient space around it must be provided

to guarantee adequate ventilation of the device (see figs. 2a).

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Xtender

User manual V4.6.0 10

3.5.1 Fastening of the XTH model

First fix the mounting bracket (26) supplied with the device using 2 Ø < 6-8 mm >screws**.

Then hang the Xtender on the bracket. Fasten the unit permanently using 2 Ø <6-8 mm> screws** on

to the two notches located at the underside of the case.

Dimensions of the appliances are given on Fig 2a of the appendix 1.

3.5.2 Fastening of the XTM model

First fasten the top screw (6-8mm **) without washer on a solid wall (concrete or metallic wall) up to

a distance of 2mm between head and wall. Hang the device from the screw. If deemed necessary,

the upper support screw can be fully tightened after hanging the device. In theory, this is only

necessary in mobile applications. To access the upper support screw to fully tighten it, remove the

upper plastic grate (see 27 fig. 2a of the appendix).

Dismount the lower plastic grate of the device giving access to the wiring compartment. Carefully

fix the device with two screws (Ø 6-8 mm) in the two holes located at the bottom left and right of the

wiring compartment.

If the Xtender is installed in a closed cabinet this must have sufficient ventilation to guarantee an

ambient temperature that conforms to the operation of the Xtender.

**: These items are not delivered with the device.

It is imperative to ensure complete and safe fastening of the device. A device that is simply

hung may detach and cause severe damage.

3.5.3 Fastening of the XTS model

The XTS enclosure must be first mounted on the support plate with

the 4 screws and washer delivered with the appliance according

with figure aside. Then the unit can be fixed on a heavy-duty

support (concrete or metallic wall) and positioned vertically with

cable glands oriented down. An external ventilation unit (ECF-01,

p. 37) can be installed on top of the unit before or after wall

mounting.

A distance of at least 20 cm in between and/or around the XTH devices is required in order

to guarantee sufficient ventilation.

The envelope of the XTS can reach temperatures higher

than 60°C when used for a long period near its max

power level. These high temperatures may remain

present during several tens of minutes after stopping the

unit. It is recommended to choose a place of installation

in a restricted access area, away from children or any

unauthorized person.

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Xtender

User manual V4.6.0 11

3.6 CONNECTIONS

3.6.1 General recommendations

The Xtender falls within protection class I (has a PE connection terminal). It is vital that a protective

earth is connected to the AC-In and/or AC-Out PE terminals. An additional protective earth is

located at the bottom of the unit (See sect 3.6.4 – p. 11/13, tag (17)).

In all cases, the PE conductor for the equipment must at least be connected to the PE for

all equipment in protection class I upstream and downstream of the Xtender (equipotential

bonding). It is mandatory that the legislation in force for the application concerned be

adhered to.

Tighten of the input (13) and output (14) terminals by means of a no. 3 screwdriver (minimum 1.2 Nm

tightening torque) and those for the remote entry ("REMOTE ON/OFF") (7) and "AUX.CONTAC" (8) by

means of a no. 1 screwdriver (0.55 Nm tightening torque).

The cable cross-sections of these terminals must conform to local regulations.

All connection cables as well as the battery cables must be mounted using cable restraints in order

to avoid any traction on the connection.

Battery cables must also be as short as possible and the cross-section must conform with the

applicable regulations and standards. Sufficiently tighten the clamps on the "battery" inputs (fig. 4a

(11) and (12) (10 Nm tightening torque).

Before connecting or disconnecting the entry or exit cables AC-In (13) and AC-Out (14), the

installer must make sure that there is no voltage present in the cables OR on the terminals.

Before connecting the battery, the installer must make sure that the AC-In source and the

AC-Out loads are well disconnected.

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User manual V4.6.0 12

3.6.2 Connection compartment, XTH and XTM models

The unit’s connection compartment must remain permanently closed when in operation.

It is imperative to close the protection cap on the connection terminals after each

intervention in the device.

After opening, check that all sources of AC and DC voltage (batteries) have been

disconnected or put out of service.

Some accessible part inside the compartment can have surface temperature higher than

60°C. Wait for the complete cooling of the unit before opening the compartment.

Any unused cable entry on the device must be sealed to prevent any intrusion. An intrusion

of small animals in the unit may cause serious damage not covered by warranty.

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User manual V4.6.0 13

3.6.3 Connection compartment, XTS model

Any unused cable entry on the device must be sealed to prevent any intrusion. An intrusion

of small animals in the unit may cause serious damage not covered by warranty.

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User manual V4.6.0 14

3.6.4 Elements of the connection compartments

Note: The left part of figure A shows the positions of elements (2, 3, 4, 5 and 15) as placed in recent

devices. Figure B shows the positions of elements 2, 3, 4, 5 and 15 as placed on the communication

module TCM-01 present in older versions of the device and described in chapter 9.4.

The functionalities of the device are identical in both configurations.

Pos.

Denomination

Description

Comment

Protective earth connection

terminal

This terminal is used as primary earth

connection protection. (see chapter.

3.6.1– p. 11)

ON/OFF

Main switch

Main on/off switch

See sect. 11.1 – p. 39.

In XTM and XTS series, this function is

deported on the remote command

module RCM-10. See sect. 9.3 – p. 36.

Temp. Sens

Connector for the battery

temperature sensor

See sect. 9.2 – p. 36. Only connect the

original Studer BTS-01 sensor.

Com. Bus

Double connector for

connecting peripherals such as

the RCC-02/03 or other

Xtender units

Only Studer compatible device can be

connected. The connection of any other

device (LAN etc.) may damage the

device. See chapter 4.5.9 – p. 23.

O / T

(Open /

Terminated)

Switch for terminating the

communication bus.

Set position (open) if the 2

connectors (3) are occupied.

Set position T if only one is

occupied.

On model XTH, the 2 termination switches

(4) must be in the same position: either

both in position O (open) or both in

position T (terminated).

3.3 V (CR-2032) lithium ion type

battery socket

Used as a permanent supply for the

internal clock. See sect. 7.6 - p. 31.

Jumper for programming the

off/on switch by dry contact

See sect. 7.7 – p. 31 and fig. 8b point (6)

and (7). They are positioned at A-1/2 and

B-2/3 by default.

Remote entry

(REMOTE

ON/OFF)

Remote entry terminals.

In XTM series, this entry is

deported on the remote

command module RCM-10.

See sect. 9.3 – p. 36

Allows the control of a function – to be

defined by programming – by the closing

of a dry contact or by the presence of a

voltage across these terminals. See sect.

7.7 – p. 31).

AUXILLARY

CONTACT

Auxiliary contact

For XTS model, available only

with module ARM-02 (see sect.

9.5 - p. 37

(See sect. 7.5 – p. 31)

Take care not to exceed the admissible

loads.

Activation indicators for

auxiliary contacts 1 and 2

See sect. 7.5 – p. 31.

L1/L2/L3

Phase selection jumpers.

See sect. 8.1. – p. 34.

Jumper default at position L1.

+BAT

Positive pole battery

connection terminals

Carefully read sect. 4.5 – p.19

Take care with the polarity of the battery

and when tightening the clamp.

-BAT

Negative pole battery

connection terminals

AC Input

Connection terminals for the

alternative power supply

(generator or public network)

See sect. 4.5.7 - p. 23.

Note: It is imperative that the PE terminal

be connected.

AC Output

Connection terminals for the

device output.

See sect. 4.5.6 - p. 23.

Note: Increased voltages may appear

on the terminals, even in the absence of

voltage at the input of the inverter.

RCM-10

Connector for RCM-10 module

Only on XTM and XTS. See sect. 9.3 – p. 36

I-CHAR

Rotating knob to adjust the

battery charge current

Only in XTS model.

Studer Innotec SA

Xtender

User manual V4.6.0 15

Pos.

Denomination

Description

Comment

Connection for supplementary

protective earth.

This connection can also be used as

principal protective earth. See sect.

3.6.1– p. 11.

INPUT LIMIT

Rotating knob to adjust the

input current limit

Only in XTS model. For other models, see

sect. 7.2.2 – p. 27.

OFF/ON

S/Boost

Activation of source assistance

"Smart boost" function

Only in XTS model. For other models, see

sect. 7.2.2.4 – p. 28.

OFF/ON

UPS

Setting of sensitivity of the

detection of AC input loss:

OFF=tolerant / ON=Fast

Only in XTS model. For other models, see

section. 7.2.1 – p. 27.

16A

AC input protective device: Only on XTS model. This protective device will

trip in case of excessive load when the XTS is connected to an

unprotected source higher than 16A.

It can be reset after removing the default downstream (load too high) and

upstream (source greater than 16A. (check the unit is connected thru an

upstream protective device (fuse or circuit breaker) max. 16 A.

3.6.5 Tightening torque

The tightening torque of different connection points should be checked regularly, especially in

installations exposed to strong vibrations (mobile systems, vehicles, boats,…). The table below states

the recommended tightening torques for each connection:

Location

XTH

XTM

XTS

AC connector

1,6 Nm,

with the exception of AC-Out for

XTH 8000-48 : 4Nm

1,6 Nm

to clip on

DC screw

10 Nm

4 Nm

Exterior (only XTS)

5 Nm

3.6.6 Max permissible cable cross-sections

The cable cross-section should be defined according to the information in chap. 4.5.1. The max

permissible cable cross-section for each device is defined by the size of the corresponding cable gland,

which is indicated in the below table:

XTH

XTM

XTS

Max Section AC [mm2]

/ Cable gland

10, 25 for XT 8000 /

PG21

10 / PG21

4 / PG16

Max Section DC [mm2]

/ Cable gland

95 / PG21

35 / PG16

Max section auxiliary relay

/ Cable gland

2,5 / PG13.5

2,5 / no cable gland

(ARM-02)

Studer Innotec SA

Xtender

User manual V4.6.0 16

4 CABLING

The connection of the Xtender inverter / charger is an important step of the installation.

It may only be carried out by qualified personnel and in accordance with the applicable local

regulations and standards. The installation must always comply with these standards.

Pay attention that connections are completely tightened and that each wire is connected at the

right place.

All cables must be insulated. The IEC/EN 62109-1 norm states requires that the cables must be

insulated with PVC, TFE, PTFE, FEP, neoprene or polyimide.

4.1 CHOICE OF SYSTEM

The Xtender may be used in different system types, each of which must meet the standards and

particular requirements associated with the application or site of installation. Only an appropriately

qualified installer can advise you effectively on the applicable standards with regard to the various

systems and the country concerned.

Examples of cabling are presented in appendix I of this manual, fig. 5 and following. Please carefully

read the notes associated with these examples in the tables on p. 33 and following.

4.1.1 Hybrid stand-alone systems

The Xtender can be used as a primary supply system for off-grid sites where a renewable energy

source (solar, wind or hydraulic) is generally available and a generator is used as backup. In this case,

batteries are generally recharged by a supply source such as solar modules, wind power or small

hydropower systems. These supply sources must have their own voltage and/or current regulation

system and are connected directly to the battery. (Example, fig. 11)

When the energy supply is insufficient, a generator is used as a back-up energy source. This allows

the batteries to be recharged and direct supply to consumers via the Xtender transfer relay.

4.1.2 Grid-connected back-up systems

The Xtender can be used in a back-up system, also known as an uninterruptible power supply (UPS)

– enabling a reliable supply to a site connected to an unreliable network. In the event of an

interruption to the energy supply from the public network, the Xtender, connected to a battery,

substitutes the faulty source and enables a support supply to the users connected downstream. These

will be supplied as long as the energy stored in the battery is sufficient. The battery will quickly be

recharged at the next reconnection to the public grid.

Various application examples are described in figs. 8a – 8c in appendix 1.

4.1.3 Integrated mobile systems

These systems are meant to be temporarily connected to the grid and ensure the supply of the

mobile system when this is disconnected from the grid. The main applications are for boats, service

vehicles and leisure vehicles. In these cases, two separate AC inputs are often required, one

connected to the grid and the other connected to an on-board generator. Switching between two

sources must be carried out using an automatic or manual reversing switch, conforming to the

applicable local regulations. The Xtender has a single AC input.

Various application examples are described in figs. 10a – 10b – 10c.

4.1.4 Multi-unit systems

Whatever system is selected, it is possible to realise systems composed of several units of the same

type and the same power output. Up to three Xtender in parallel or three extenders forming a three-

phase grid or three times two or three Xtender in parallel forming a three-phase / parallel grid, may

be thus combined.

The use of Xtenders in a UPS back-up system must be carried out by qualified personnel who

have been checked by the responsible local authorities. The diagrams in the appendix are

given for information and as a supplement. The applicable local standards and regulations

must be adhered to.

Studer Innotec SA

Xtender

User manual V4.6.0 17

4.1.5 Distributed minigrid

The implementation of the Xtender on top of a distributed minigrid (beyond the main building)

requires special care in choosing the distribution system.

Studer Innotec recommends a TT distribution for the DC grid as well as for the AC grid.

The size of the grid increases greatly the exposure of the inverters to atmospheric

overvoltage and to non-equipotentiality in the grid. This is particularly noticeable in the aerial

distribution grids. In this case, very special care must be taken to implement correctly all

protection measures of the installation.

4.2 EARTHING SYSTEM

The Xtender is a protection class I unit, which is intended for cabling in a grid type TT, TN-S or TNC-S.

The earthing of the neutral conductor (E) is carried out at a sole installation point, upstream of the

RCD circuit breaker (D) type A, 30 mA.

The Xtender can be operated with any earthing system. In all cases it is imperative that the protective

earth be connected in compliance with the applicable standards and regulations. The information,

notes, recommendations and diagram mentioned in this manual are subject to local installation

regulations in every case. The installer is responsible for the conformity of the installation with the

applicable local standards.

4.2.1 Mobile installation or installation connected to the grid via plug

connector

When the input of the device is connected directly to the grid via a plug, the length of the cable

must not exceed 2 m and the plug must remain accessible.

In the absence of voltage at the input, the neutral and live are interrupted, thereby guaranteeing

complete isolation and protection of the cabling upstream of the Xtender.

The earthing system downstream of the Xtender is determined by the upstream earthing system when

the grid is present. In the absence of the grid, the earthing system downstream of the inverter is in

isolated mode. The safety of the installation is guaranteed by the equipotential bonding.

The connection (link) between the neutrals (C) upstream and downstream of the Xtender

is not permitted in this configuration.

This connection type guarantees the optimal continuity for supplying the Xtender loads. The first

isolation fault will not lead to an interruption in the supply.

If the installation requires the use of a permanent isolation controller this would have to be de-

activated when the TT network is present at the Xtender input.

All sockets and protection class I devices connected downstream of the Xtender must be

properly connected to the earth (earthed socket). The cabling rules above remain valid,

including in installations, in all cases where the Xtender input is connected to the grid via a

plug connector.

The IT system is not recommended for the distribution. This kind of distribution is most of the

time forbidden by the local laws. The achievement of low voltage electric system is always

subject to local laws and must imperatively be implemented and controlled by qualified

and professionally authorized staff. Studer Innotec accepts no liability for damages due to

non-conforming installation and to the lack of compliance with the local rules or with the

recommendations of this manual.

Studer Innotec SA

Xtender

User manual V4.6.0 18

4.2.2 Stationary installation

The installation may be equivalent to a mobile installation (with interrupted neutral).

In a fixed installation where the neutral is connected to the earth at a single installation point

upstream of the Xtender, it is permissible to carry out a connection of the neutrals in order to preserve

an unchanged earthing system downstream, independent of the operating mode of the Xtender.

This choice has the advantage of keeping the protection devices downstream of the Xtender. This

connection can be executed according to the examples in appendix 1, or carried out by modifying

the parameter {1486}.

In this case, the appearance of the first fault will lead to the installation stopping or the disconnection

of the protection devices upstream and/or downstream of the Xtender.

Safety is guaranteed by the equipotential bonding and by any RCD circuit breakers placed

downstream.

This connection (C) is not permitted if a socket is installed upstream of the Xtender.

4.2.3 Installation with automatic PE-neutral switching

In certain applications, it is desirable to keep the neutral upstream and downstream of the Xtender

separated (C) while re-establishing the earthing system (TN-S, TT or TNC-S) in the absence of voltage

at the input. This functionality is forbidden by default by the parameter {1485}. This parameter can

be modified by the parameter {1485} via the RCC-02/-03 remote control. This modification must be

carried out possessing technical knowledge, at the responsibility of the installer and in conformity

with the applicable regulations and standards.

The authorization of this function adheres to the requirements for an earth-neutral connection at the

source.

4.2.4 Lightning protection

As per the installation site, it is highly recommended to set a protection strategy to protect your

installation against lightning. The strategies depend on various parameters directly linked to each site

and we recommend therefore dealing very professionally with this issue.

Damages due to lightning often result in significant costs (full replacing of the printed

electronic board) and are not covered by Studer Innotec’s warranty.

4.3 RECOMMENDATIONS FOR DIMENSIONING THE SYSTEM

4.3.1 Dimensioning the battery

The battery capacity is dimensioned according to the requirements of the user – that is 5 to 10 times

its average daily consumption. The discharge depth of the battery will therefore be limited and the

service life of the battery will be extended.

On the other hand, the Xtender must have a battery capacity that is large enough to be able to

take full advantage of the performance of the equipment. The minimum capacity of the batteries

(expressed in Ah) is generally dimensioned in the following way: five times the rated power output

of the Xtender / the battery voltage. For example, the model XTH 8048 must have a battery of a

minimum capacity of 7000*5/48=730 Ah (C 10). Because of the inverter’s extreme overload capacity,

it is often recommended that this value be rounded up. An under-dimensioned battery may lead to

an accidental and undesired stopping of the Xtender in the event of high instances of use. This

stoppage will be due to a voltage that is insufficient on the battery, subject to a strong discharge

current.

The battery will be selected with regard to the greatest value resulting from the calculations set out

above.

The battery capacity determines the adjustment of the parameter {1137} "battery charge current".

A value between 0.1 and 0.2 x C batt. [Ah] (C10) enables an optimum charge to be guaranteed.

The methods proposed to dimension the batteries; inverter and generator are strictly

indicative and in no way constitutes a guarantee of perfect dimensioning. The installer is

solely responsible for good dimensioning and installation.

Studer Innotec SA

Xtender

User manual V4.6.0 19

4.3.2 Dimensioning the inverter

The inverter is dimensioned in such a way that the rated power output covers the power of all the

consumers, which will be used at the same time. A dimensioning margin of 20 to 30% is recommended

to guarantee that the Xtender will work well in an ambient temperature of more than 25 °C.

4.3.3 Dimensioning the generator

The power output of the generator must be the same or more than the average daily power.

Optimally, it should be two or three times this power. Thanks to the input limit function (see sect. 7.2.2

- p. 27) it is not necessary to over-dimension the generator. Indeed, the loads that are temporarily

higher than the power of the generator will be supplied by the inverter.

Ideally, the generator should not have a power output by phase that is less than half of the power of

the Xtender(s) present at this phase.

The power available downstream of the inverter when the generator is working is the same

as the sum of the two powers if the Smart Boost function is activated. The sum of the currents

is limited to a maximum of 57A (80A for the models XTH 8000-48, XTH 6000-48-01 and XTH

5000-24-01). This sum is limited to 20A in XTS model.

4.3.4 Dimensioning the renewable energy sources

In a hybrid system, the alternative energy sources such as the solar generator, wind power and small

hydropower should, in principle, be dimensioned in such a way as to be able to cover the average

daily consumption.

4.4 WIRING DIAGRAMS

Several schematics and wiring comments as in the

diagram to the right are proposed in Annex I of this

manual.

The diagram to the right gives an example of a hybrid

system for a remote site with some renewable energy

sources and single-phase generator.

These diagrams are indicative, and in any case, the

wiring is subsidiary to compliance with local standards

and practices, under the responsibility of the installer.

Comments regarding the letters / and / or numbers

cited in the diagram aside and of those in the

appendix are given in sect. 16 to 19.

The elements of these diagrams are referenced by a

capital letter when related to the alternating current

(AC) elements.

The elements referenced by a lowercase letter relate

to the direct current elements (DC part of the

diagram.)

4.5 CONNECTING THE BATTERY

The terminals of DC input / output of the apparatus

(11) - (12) p. 9 are intended to be exclusively

connected to a battery, usually of lead acid batteries with gelled or liquid electrolyte

The use of other battery types like Ni-Cd, Li-Ion or other is possible subject to a proper setting of load

profile in accordance with the specifications of the manufacturer of the battery and under the

responsibility of the installer.

The use of the Xtender connected to any other type of DC source without battery (buffer) is

strictly prohibited and may cause significant damage to the device and / or the source.

Studer Innotec SA

Xtender

User manual V4.6.0 20

Lead batteries are usually available in 2 V, 6 V or 12 V block types. In the majority of cases, in order

to obtain an operating voltage that is correct for Xtender usage, several batteries must be

connected in series or in parallel depending on the circumstances.

The various cabling options are presented in figures 5a-5b (12 V), 5c-5e (24 V) and 6a to 6d (48 V) in

appendix I of this manual.

4.5.1 Battery cable cross-section and DC protective devices

The battery cables must also be as short as possible.

It is always preferable to keep the cable at the negative

pole of the battery as short as possible.

In order to avoid any further loss and protection

redundancy, the XTH does not have an internal fuse.

A protective device (f) must be installed as close as

possible to the battery and sized according to the table

on the left.

The recommended cable cross-sections are valid for

lengths less than 3 m. beyond this length it is strongly

recommended to oversize the battery cables.

For safety reasons, we recommend an annual check on

the tightness of all connections.

In mobile installations, the tightness of the connections

should be checked even more frequently.

4.5.2 Connecting the battery (Xtender side)

Insert the cable glands supplied on the battery cable before tightening the cable lugs. Crimp the

cable lugs and fasten the cable gland on the device. Repeat this for the second battery cable. Fix

the battery cables to the appropriate connections "+ Battery" and "- Battery". The M8 screws must be

very well tightened.

On the XTM range, you can insert, if required, a fuse directly on the positive connection to the battery

following the procedure below.

Each Xtender is connected directly to the battery through its own protective device (fuse or

circuit breaker. It should never be connected to the output of a DC voltage regulator like

solar regulator, without having the battery as buffer.

All other consumers or sources are connected directly to the battery by their own protective

devices. (See details (f) on Fig. 11-18)

In multi-unit systems, all Xtenders from the same system must be connected according to the

same battery bank.

The battery cables must be protected by one of the following measures in all cases:

- protection device (fuse) at each pole

- protection device (fuse) on the pole not connected to the earth

Range

Battery

fuse

Cable cross-

section (<3m)

XTS-900-12

100A

25mm2

XTS 1200-24

80A

25mm2

XTS-1400-48

50A

16mm2

XTM-4000-48

200A

50mm2

XTM-2600-48

150A

35mm2

XTM-3500-24

300A

70mm2

XTM-2400-24

200A

50mm2

XTM-2000-12

300A

70mm2

XTM-1500-12

250A

70mm2

XTH-8000-48

300A

95mm2

XTH-6000-48

300A

70mm2

XTH-5000-24

300A

95mm2

XTH-3000-12

350A

95mm2

The cable lugs must be carefully fixed and

tightened sufficiently to guarantee minimum

loss. Insufficient tightening may cause

dangerous heating at the connection point.

The XTS is equipped with an electronic protection device protecting it from accidental

reversal of polarity of the battery. This does not exempt of installing a protective device close

to the battery.

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